Construction assembly made with fiber glass

ABSTRACT

Provided is a construction assembly comprising: a. a base; b. a layer of glass fiber placed directly on the base; and c. a decorative layer having a plurality of tiles placed immediately on the glass fiber, wherein the glass fiber is mixed with a hardener and a resin to attach the glass fiber directly to the base and the decorative layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. provisionalapplication Ser. No. 62/694,891, filed on Jul. 6, 2018, the contents ofwhich are hereby incorporated by reference.

BACKGROUND SECTION OF THE INVENTION

There are many places in a structure where tiles are placed, includingwalls, decks, roofs, flooring, and building facades. A problem withstructures having tiles is that the structure may too rigid, resultingin excess noise when a person walks on a tile or resulting in breakingof the tiles. In addition, the underlying wood of the structure may beprone to a termite infestation. In case of a roof, the pre-existingstructures are prone to fires, wind, and lack of uniformity andinsulation. There is a need in the art for a construction method andstructure that addresses these drawbacks.

SUMMARY SECTION OF THE INVENTION

Provided is a construction assembly comprising: a. a base; b. a layer ofglass fiber placed directly on the base; and c. a decorative layerhaving a plurality of tiles placed immediately on the glass fiber,wherein the glass fiber is mixed with a hardener and a resin to attachthe glass fiber directly to the base and the decorative layer. Thehardener percentage compared to the resin can be between 1%-2%weight/weight at STP. The glass fiber can be in form of a sheet. Theglass fibers can be in form of chopped fibers. Optionally, an additionalchemical compound acting an adhesive is not used in between the fiberglass and the decorative layer. The resin can be selected from the groupconsisting of one or more of polyester, vinyl ester, epoxy resin,isophthalic, and mixture thereof. The resin can be a polyester resin,the hardener is Methyl Ethyl Ketone Peroxide (MEKP). The combination ofthe percentage of the hardener can be 1 to 1.25 relative to thepolyester weight/weight at STP. The combination of the percentage of thehardener can be 1 to 1.1 relative to the polyester weight/weight at STP.The base can be made from wood, metal or concrete. The base can be madefrom wood with a pre-applied layer of caulking to fill any of the gapsof the base. The hardener can be an aliphatic, cycloaliphatic, or anaromatic amine and the resin is epoxy based. Calcium Carbonate is addedto the mixture of the hardener and the resin.

Provided is a construction assembly made by a process comprising thesteps of: a. combining a hardener with a resin to obtain a mixture; b.placing glass fibers on top of a base; c. applying the mixture to theglass fibers on the wood; and d. placing tiles on the glass fibers thatarea treated by the mixture.

Provided is a roof construction assembly comprising: a. a top and abottom board made from wood; b. a plurality of rafters for connectingthe boards; c. a plurality of plastic foams placed on between therafters; and d. a layer of glass fiber under the bottom layer. Theconstruction assembly can be prefabricated. A bracket can extend fromtop of the assembly. A layer of glass fiber can be on top of the topboard, and a plurality of decorative elements on top of the fiberglass.The plastic foams can be in form of a sheet. A level of cement or gypsumcan be below the glass fiber on the bottom board. The layer offiberglass can be all around the assembly.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 illustrates a cross-section view of an assembly with a wood base,a fiberglass layer, and a decorative layer of tiles. Also illustrated isplaster used to fill the gaps between the tiles and deformities in thewood base.

FIG. 2 illustrates the steps of the process in making the assembly.

FIG. 3A illustrates a pre-fabricated roof section or panel box.

FIG. 3B illustrates a blow-up of FIG. 3A.

FIG. 4 illustrates chopped glass fibers.

FIG. 5 illustrates a glass fiber sheet.

FIG. 6 illustrates a metal wall/panel before installation of tiles.

FIG. 7 illustrates the metal wall/panel of FIG. 6 after tileinstallation.

DETAILED DESCRIPTION OF THE INVENTION

Provided is a method for putting tiles 3 and other similar decorativeproducts on walls, decks, roofs, flooring, building facades, kitchencounters, walls, and patio grills. The base 1 of the structure can be awooden or metal base. The base 1 can be perforated or non-perforatedmetal, wood, GRP (Glass Reinforced Plastic), or FRP (Fiber-reinforcedplastic) structure. A fiberglass 2 layer is placed immediately above thebase 1 in physical contact with the base 1, and decorative members suchas tiles 3 and stones on top, also in physical contact with the fiberglass 2 layer. These products are easy to install, strong and leakproof. They are also fire, cold, warm, wind and sunlight resistant, andtherefore have high durability. This method of construction can be usedin many different applications especially in custom designed houses,residential homes, and apartments. Other uses include use in overheadshades for parking and solar panels.

The base 1 can be made from a perforated or non-perforated metal, wood,GRP (Glass Reinforced Plastic), or FRP. Fiber-reinforced plastic (FRP)(also called fiber-reinforced polymer, or fiber-reinforced plastic) is acomposite material made of a polymer matrix reinforced with fibers. Thebase 1 can for example be a drywall or floor for placement of a tile.The base 1 can be the wooden support of a roof.

Glass fibers 2 are put immediately on top of the base 1. Fiberglass 2layers, with different fabric reinforcements such as cloth, matt,roving, KNYTEX (made with a stitch-bonding process by combining layersof ±45° unidirectional fabric with chopped strand mat), with differentweights, and different materials such as E-Glass (alumino-borosilicateglass with less than 1% w/w alkali oxides, mainly used forglass-reinforced plastics), S-Glass (alumino silicate glass without CaObut with high MgO content with high tensile strength), carbon, graphite,carbon fiber, and Aramid (TWARON and KEVLAR) can be used as the fiberreinforcement.

Decorative products, such as tiles, stones, porcelain, ceramic, andfacade bricks are placed immediately on the glass fiber 2.

To activate the glass fibers 2, a mixture 8 of a resin 31 and a catalysthardener 30 is added to the glass 2 fibers. The mixture 31 can furtheroptionally have calcium carbonate 32. After the mixture is applied tothe glass fibers 2, the glass fibers 2 form a viscous sticky liquid,which is optimal for placement of tiles. An additional layer of adhesiveis not needed.

Examples of resins 31 include polyester, vinyl ester, epoxy resin, andisophthalic.

Examples of hardeners 30 include Methyl Ethyl Ketone Peroxide (MEKP) andamines, such an aliphatic, cycloaliphatic, or an aromatic amine.

Hardener percentage can be between 1%-2% weight/weight compared to theresin at STP (Standard temperature and pressure).

Caulking 4, plaster and other filling agents can be used to fill inbetween the tiles or fill in the base 1 (if perforated metal, woven wiremesh or if the wood has imperfections).

The fiberglass 2 layer after activation with the resin/hardener, acts asthe binder between the base 1 structure and the decorative products suchas tiles 3.

Different resins 31 such as polyester, vinyl ester, epoxy resin, orisophthalic and their hardeners 30 can be used in the fiberglass 2layers to adhere all the components together.

These construction assemblies can be either pre-made (prefabricated) andget installed later or they can be made onsite depending on theapplication. For example, in applications for walls, precast sheets ofthis assembly can be attached to building posts using bolts and nuts.For flooring applications, they can be made onsite. For example,fiberglass 2 can be put on top of dried cement and tiles 3, stones, andcan be put on top, or the precast sheets can be installed on top ofcement using expansion anchor bolts. For wooden roofs with small slopes,the layers of fiberglass 2 and then tiles 3, stones, bricks, or othermaterials can be installed on top of it onsite. For high slope roofs,precast roofs (as illustrated in FIG. 3A) can be used instead. If one ofthe components is already present (for example, wooden roofs or floors),the other two layers can be installed on site. In case of light slopesor flat roofs it can be done on site otherwise in steeped roofs, theprecast option is used which is faster and easier to install.

The base 1 layer can be made of wood, metal or concrete. The preferredbase 1 for use can be wood. When making the assembly, a completely drywood is used with all the cracks and small grooves filled, such as withfiberglass 2. Caulking 4 can be used to fill spaces between differentboards. Use of resin 31 in fiberglass 2 makes the base 1 more resistantto termites.

After caulking 4, the surface can be leveled and smoothed by sand paper.Two or three fiberglass 2 layers can be used for ordinaryroof/floor/deck/wall. To increase flexibility and cushioning property ofthe roofs/floors/deck, especially when the base 1 is made of wood, it ispreferred to use excess layers of fiberglass 2. In this embodiment, acombination of chopped fiber glass (FIG. 4), hardener, and resin mixedand spread only over the last layer with rollers can be used. In steepedroofs, the start point is the lowest level of the roof. First, a layerof fiber glass 2A is placed. The a galvanized, aluminum or stainlesssteel angle/bracket 16 with the same thickness of tile/ceramic/porcelainor stone is installed at the edge of wood (base 1) and tightened withnail or screw (or other fastener) (as illustrated in FIG. 3A).Application of fiberglass 2 layers can start from the vertical part ofthe angle/bracket 16 and can extend to the highest point of the roof,usually the ridge. The seams of fiberglass 2 layers optimally do notcoincide on each other and each layer overlaps with the next layer. FIG.3B is a blow-up of FIG. 3A.

Use of rollers to prevent formation of air bubbles is preferred. Afterputting the second layer of fiberglass 2 let it dry for 24 hours, thenthe third layer and tiles will be applied. Caulking 4 will be done after24 hours of putting tiles. Fiberglass 2 layer made of hardener 1% ismore flexible than fiberglass 2 made of denser hardener. Besttemperature range is between 65-75 degrees Fahrenheit. Fiberglass geltime is between 15-25 minutes depending on temperature and amount ofhardener. Best time for installing the tiles is before gel time. Spacercan be used to build certain space for caulking 4 between tiles. Finalcaulking 4 is preferably done at least 24 hours after installing tiles.Different colors can be added for a better look of caulking 4.

Perforated sheet metal used for a wall is preferred over non-perforatedbecause bilateral connection is made through the holes. A layer offiberglass 2 is attached to the surface of tile 3(stones/ceramics/porcelains). An additional layer of fiber glass can beused for heavier stones/ceramics/tiles. After 24 hours, when it iscompletely dry, it would then adhere to fresh outer fiberglass 2 layerof the wall/roof. The procedure of using different resins is the same.

The following table illustrates the amount of MEKP used for polyesterand vinyl ester resin, preferably polyester resin:

Polyester Resin 1.25% Weight to weight 1% MEKP MEKP 1.5% MEKP 1.75% 4ounces 1/32 Ounces 1.50 ounces 1.75 ounces 1/16+

Other resin and hardener combinations can also be used. For example, ifan epoxy resin is used, the hardener can be an aliphatic,cycloaliphatic, or an aromatic amine for epoxy.

FIG. 1 illustrates a cross-section view of an assembly with a wood base1, a fiberglass 2 layer, and a decorative layer of tiles. As illustratedin this drawing, a fiberglass layer 2 can be placed on base 1. The fiberglass 1 can be in form of fibers of FIG. 4 or sheets of FIG. 5. Thefiber glass 2 is placed directly on the base 1. Tiles 3 are based on topof the fiber glass 2. The tiles 3 and the base 1 both adhere to fiberglass 2 without the need for an additional adhesive layer. Caulking 4can be used in between the tiles 3.

FIG. 2 illustrates the steps of the process in making the assembly. Thefiber glass, either in form of sheets, chopped, or mixtures thereof isplaced 7 on the base 1. In a separate container, a hardener is mixed 8with a resin. The mix is applied 10 to the fiber glass. A roller can beused to make the application uniform. Tiles 3 are placed 11 before theactivated fiber glass is hardened.

FIG. 3A illustrates a pre-fabricated roof section or a panel box. Thepre-fabricated roof section or other structure can be made from a base 1cover placed on top and another cover 13, placed on the bottom. In oneembodiment, base 1 and cover 13 are sheets of wood. Board 1 can bethicker than board 13. Both boards 1 and 13 can be less than about oneinch in thickness. Rafters 14 attach base/sheet 1 to sheet 13. Aplurality of rafters 14, preferably also made out of wood, can be placedwhile maintaining a gap in between them. Rafters 14 can also be made upof aluminum or FRP. A water resistant material such as plastic sheet 50,such as plastic foam (Styrofoam-closed-cell extruded polystyrene foam)(Yonolit) can be placed in between the gaps of rafters 14 to addstructural flexibility and ability to withstand compression. Foamedplastic 50 is a synthetic resin converted into a sponge like mass with aclosed-cell or open-cell structure. The height/thickness of the rafters14 can be the same as that of the plastic sheet 50. Bracket 16 can beinstalled all along one or more sides of the base 1 for holding tiles 3in place on case the roof has an angle. The bracket 16 can be put on thebottom of the incline and the two sides. The prefabricated roof can comewith an optional layer of fiber glass 2A all around. Layer 2A canincrease the tensile strength of the pre-fabricated roof or otherassemblies in the same manner that a post-tension wire does. Thepre-fabricated structure can have an optional fiber glass layer 2A allor partially around the structure (up to all six sides of the panelbox). Just like FIG. 1, a fiber glass layer is placed on base 1, and thetiles 3 are placed on top of base 1, which is a wooden sheet. Caulking 4can be used in between the tiles. The pre-fabricated roof is placed on awall or column 51. The lower section of the roof that is placed insidethe structure can be covered with plaster/gypsum 18. Cement 17 can beused to cover portions of the roof that are outside of the structure.Instead of cement 17 and gypsum 18, decorative panels and tiles can alsobe used. FIG. 3B is a blow-up of FIG. 3A.

FIG. 6 illustrates a metal wall 23 before installation of tiles. Metalwall 23 can be held in place by posts 21 and top frame 22. Posts 21 canbe held in place by attachment to concrete 20. A gap can exist belowmetal wall 23. FIG. 7 illustrates installation of tiles on both sides ofwall 23, in the same way shown in FIG. 1.

What is claimed is:
 1. A construction assembly comprising: a. a base; b.a layer of glass fiber placed directly on the base; and c. a decorativelayer having a plurality of tiles placed immediately on the glass fiber,wherein the glass fiber is mixed with a hardener and a resin to attachthe glass fiber directly to the base and the decorative layer.
 2. Theconstruction assembly of claim 1, wherein the hardener percentagecompared to the resin is between 1%-2% weight/weight at STP.
 3. Theconstruction assembly of claim 1, wherein the glass fiber is in form ofa sheet.
 4. The construction assembly of claim 1, wherein the glassfibers are in form of chopped fibers.
 5. The construction assembly ofclaim 1, wherein an additional chemical compound acting an adhesive isnot used in between the fiber glass and the decorative layer.
 6. Theconstruction assembly of claim 1, wherein the resin is selected from thegroup consisting of one or more of polyester, vinyl ester, epoxy resin,isophthalic, and mixture thereof.
 7. The construction assembly of claim1, wherein the resin is a polyester resin, the hardener is Methyl EthylKetone Peroxide (MEKP).
 8. The construction assembly of claim 7, whereinthe combination of the percentage of the hardener is 1 to 1.25 relativeto the polyester weight/weight at STP.
 9. The construction assembly ofclaim 7, wherein the combination of the percentage of the hardener is 1to 1.1 relative to the polyester weight/weight at STP.
 10. Theconstruction assembly of claim 1, wherein the base is made from wood,metal or concrete.
 11. The construction assembly of claim 1, wherein thebase is made from wood with a pre-applied layer of caulking to fill anyof the gaps of the base.
 12. The construction assembly of claim 1,wherein the hardener is an aliphatic, cycloaliphatic, or an aromaticamine and the resin is epoxy based.
 13. The construction assembly ofclaim 1, wherein Calcium Carbonate is added to the mixture of thehardener and the resin.
 14. A construction assembly made by a processcomprising the steps of: a. combining a hardener with a resin to obtaina mixture; b. placing glass fibers on top of a base; c. applying themixture to the glass fibers on the wood; and d. placing tiles on theglass fibers that area treated by the mixture.
 15. A roof constructionassembly comprising: a. a top and a bottom board made from wood; b. aplurality of rafters for connecting the boards; c. a plurality ofplastic foams placed on between the rafters; and d. a layer of glassfiber under the bottom layer.
 16. The roof assembly of claim 15, whereinthe construction assembly is prefabricated.
 17. The roof assembly ofclaim 15, further comprising a bracket extending from top of theassembly.
 18. The roof assembly of claim 15, further comprising a layerof glass fiber on top of the top board, and a plurality of decorativeelements on top of the fiberglass.
 19. The roof assembly of claim 15,wherein the plastic foams are in form of a sheet.
 20. The roof assemblyof claim 15, wherein the layer of fiberglass is all around the assembly.